Floating, Bottom-Filled and Twist Insert and Methods for Use Thereof

ABSTRACT

An insert, a floating nut and methods for use thereof in a panel of an aircraft are presented. Specifically, an insert includes a housing defining a cavity. An aperture is further defined in a first end of the housing and a semi-spherical portion is defined at a second end of the housing. A pair of vent openings are also defined on opposing sides of the first end of the housing.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of the filing date of U.S.Non-Provisional patent application Ser. No. 14/797,579, filed Jul. 13,2015, which is hereby incorporated by reference in its entirety.

FIELD

The disclosure generally relates to mounts and fasteners and, moreparticularly, to an insert for use with interior panels for aircraft.

BACKGROUND

Sandwich panels are used extensively in the aircraft and marineindustries. These sandwich panels typically are made of fiberglass orsimilar material formed in a honeycomb structure. The honeycombstructure is then typically sandwiched between outer layers of aluminumpanels or the like. These sandwich panels may be used as interior panelsof the aircraft. In order to anchor objects to the sandwich panel, insetpanel fasteners are typically used.

Many types of mounting devices have been developed for holding one ormore objects to a support surface. For example, inset-type fasteners aregenerally anchored into a structure and include an engagement portion,such as the male or female threads of a screw, for securing objects tothe structure. Inset fasteners are particularly useful when a strongconnection between the structure and object cannot be readily obtainedthrough use of a surface mounted structure. Most inset panel fastenersinclude a cylindrical barrel having a central bore. The central boretypically includes female threads functioning as a fastener element.Alternatively, some inset panel fasteners include a floating fastenerelement in the form of a nut which also includes female threads which isfloatingly positioned within the bore. A flange is typically arranged atthe base of these floating nuts. In addition, the inset panel fastenermay be coupled to a flexible tab intended to stick to and hold theinsert flush within a sandwich panel and to prevent adhesive fromleaking onto the exterior of the panel.

To anchor the inset panel fastener in place, a cavity is typicallyformed directly through the outer layer (e.g., an aluminum layer) intothe honeycomb core using a drill, for example. The inset panel fastenermay then be positioned within the cavity and an adhesive or otherbinding material may be injected into the cavity to secure the fastenerto the honeycomb core. Alternatively, adhesive may be injected into thecavity of the panel first and the inset fastener may then be pressedinto the cavity of the sandwich panel.

The tab typically has pressure sensitive adhesive to removably adhere tothe skin of the sandwich panel. This tab adhesive may be weak and faildue to surface irregularity or contaminants on the skin. The tab may betoo flexible, permitting the inset panel fastener to sit above or belowthe surface of the panel or at an angle within the cavity of thesandwich panel. Further, due to the shape of the insert and installationtechniques, if the inset panel fastener is positioned too deep withinthe cavity of the panel, mark-off may show through on a decorative sideof the sandwich panel creating a visual defect. For example, the flatbottom and cylindrical shape of the inset panel fastener may act like apiston during installation forcing itself and/or the adhesive againstthe bottom of the panel cavity. In addition, during adhesive injection,the adhesive may overflow, spilling over the tab and onto the sandwichpanel surface. Still further, after the adhesive has set, a scraper maybe required to separate the tabs from the inset panel fastener andsandwich panel.

In addition, the floating fastener element typically has a threadlocking design that may create problems with thread engagement andgalling of the threads. The thread locking design may also lead tostress concentration that may result in cracking of the nut when a screwelement is introduced into the nut.

SUMMARY

An insert, a floating nut and methods for use thereof in a panel of anaircraft are disclosed herein. The advantages of the embodiments in thepresent disclosure may include, but are not limited to, improvedadhesive flow characteristics and seal with respect to the insert andthe cavity of the panel, improved insert flushness within a cavity of apanel, reduced panel mark-off on the panel, increased containment ofadhesive during insert installment and therefore a cleaner exteriorsurface of an interior panel, increased floating nut strength, decreasedfloating nut weight and reduced thread locking defects for the floatingnut.

In a first aspect of the disclosure, an insert includes a housingdefining a cavity, an aperture defined in a first end of the housing, asemi-spherical portion defined at a second end of the housing and a pairof vent openings defined on opposing sides of the first end of thehousing. In one embodiment, the insert may include a threaded floatingnut disposed within the cavity of the housing. This threaded nut maydefine a flange at a first end and define a through-hole aligned withthe aperture of the housing.

In a second aspect of the disclosure, methods for installing the insertin a panel of an aircraft are also disclosed herein. One method includesproviding an insert that comprises (a) a housing defining a cavity, (b)an aperture defined in a first end of the housing, (c) a semi-sphericalportion defined at a second end of the housing, (d) a pair of ventopenings defined on opposing sides of the first end of the housing and(e) a pair of receptacles coupled to the first end of the housing,wherein each of the pair of receptacles have sidewalls defining athrough-hole aligned with one of the pair of vent openings. Next, theinsert is installed in a cavity of a panel for an aircraft and advanceduntil the pair of receptacles rests against an exterior of a skin of thepanel. Adhesive is then injected into one of the pair of vent openings.The adhesive then flows around the housing until the adhesive exits thecavity via the other one of the pair of vent openings.

Another method includes providing an insert that comprises (a) a housingdefining a cavity, (b) an aperture defined in a first end of the housingto the cavity, (c) a semi-spherical portion defined at a second end ofthe housing, (d) a pair of vent openings defined on opposing sides ofthe first end of the housing and (e) a second aperture defined in asecond end of the housing and aligned with a central axis of thespherical portion. Next, the insert is installed in a cavity of a panelfor an aircraft. Then, a tip of an adhesive gun is placed through thefirst aperture and the cavity of the housing to the second aperture ofthe housing. An adhesive is then injected underneath the sphericalportion of the insert. The adhesive then flows around the housing untilthe adhesive exits the cavity of the panel via the pair of ventopenings.

A further method includes providing an insert that comprises (a) ahousing defining a cavity, (b) an aperture defined in a first end of thehousing, (c) a semi-spherical portion defined at a second end of thehousing, (d) a pair of vent openings defined on opposing sides of thefirst end of the housing and (e) a pair of helical grooves defined onthe exterior of the spherical portion of the housing. An adhesive isthen injected into a cavity of a panel of an aircraft. Next, the insertis installed in the cavity of the panel. Then, the adhesive flows aroundthe housing and along the pair of helical grooves until the adhesiveexits the cavity of the panel via the pair of vent openings.

The features, functions, and advantages that have been discussed can beachieved independently in various embodiments or may be combined in yetother embodiments further details of which can be seen with reference tothe following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Presently preferred embodiments are described below in conjunction withthe appended drawing figures, wherein like reference numerals refer tolike elements in the various figures, and wherein:

FIG. 1 is a diagrammatic representation of a perspective view of aninsert, according to one example embodiment;

FIG. 2 is a diagrammatic representation of a top view of an insert,including a floating nut, according to the embodiment of FIG. 1;

FIG. 3 is a diagrammatic representation of a side view of an insert,including a floating nut, according to the embodiment of FIG. 1;

FIG. 4 is a diagrammatic representation of a bottom perspective view ofan insert according to the embodiment of FIG. 1;

FIG. 5 is a diagrammatic representation of a side view of an insertaccording to the embodiment of FIG. 1, disposed in a cavity of a panel;

FIG. 6 is a diagrammatic representation of a perspective view of aninsert according to a second example embodiment;

FIG. 7 is a diagrammatic representation of a side view of an insertaccording to the embodiment of FIG. 6;

FIG. 8 is a diagrammatic representation of a perspective view of aninsert according to a third example embodiment;

FIG. 9 is a diagrammatic representation of a top view of an insert,including a floating nut, according to the embodiment of FIG. 8;

FIG. 10 is a diagrammatic representation of a side cross-sectional viewof an insert according to the embodiment of FIG. 8;

FIG. 11 is a diagrammatic representation of a bottom perspective view ofan insert, including a floating nut, according to the embodiment of FIG.8;

FIG. 12 is a diagrammatic representation of a perspective view of aninsert, according to a fourth example embodiment;

FIG. 13 is a diagrammatic representation of a side view of an insertaccording to the embodiment of FIG. 12, disposed in a cavity of a panel;

FIG. 14 is a diagrammatic representation of a side view of an insertaccording to the embodiment of FIG. 12;

FIG. 15 is a diagrammatic representation of a side cross-sectional viewof an insert according to the embodiment of FIG. 12;

FIG. 16 is a diagrammatic representation of a top view of an insertaccording to the embodiment of FIG. 12; and

FIG. 17 is a diagrammatic representation of a bottom view of an insertaccording to the embodiment of FIG. 12;

FIG. 18A is a diagrammatic representation of a top perspective view of afloating nut, according to one embodiment;

FIG. 18B is a diagrammatic representation of a bottom perspective viewof a floating nut according to the embodiment of FIG. 18A;

FIG. 19 is a flow diagram of a method for installing an insert into apanel for an aircraft, according to one example embodiment.

FIG. 20 is a flow diagram of a method for installing an insert into apanel for an aircraft, according to one example embodiment.

FIG. 21 is a flow diagram of a method for installing an insert into apanel for an aircraft, according to one example embodiment.

FIG. 22 is a diagrammatic representation of a perspective view of anaircraft that may incorporate one or more inserts in accordance with oneor more embodiments disclosed herein;

FIG. 23 is a flow diagram of an embodiment of an aircraft production andservice method of the disclosure; and

FIG. 24 is a functional block diagram of an aircraft.

Corresponding parts are marked with the same reference symbols in allfigures.

The drawings are provided for the purpose of illustrating exampleembodiments, but it is understood that the inventions are not limited tothe arrangements and instrumentalities shown in the drawings.

DETAILED DESCRIPTION

FIGS. 1-17 depict an insert 100A, B, C, D for installation in a panel105 (see FIG. 5) for an aircraft (see FIG. 22). A panel 105 refers tostructural sandwich panels that are known building components, both inrespect of conventional structures and in aircraft fabrication; thelatter being a particularly relevant environment within the context ofthe present disclosure. The popularity′ of these panels is attributableto a relatively high strength-to-weight ratio.

With reference to FIG. 5, the sandwich panels of interest are comprisedof a pair of relatively thin face sheets or skins 106 separated by andbonded or otherwise secured to an intermediate, foraminous or honeycombmember 107 of relatively thicker dimension. The skins 106 serve todistribute a load through the hone ember 107 to the supportingstructure. Depending upon the anticipated loads to which the panel 105will be subjected, a variety of materials may be utilized and certainvariations in the structural conformation of the honeycomb member 107may be employed. For example, metals, polymeric resins, and impregnatedfibrous materials have all been utilized in the past in this regard.

To anchor the insert 100A, B, C, D in place, a cavity 108 is typicallyformed directly through the skin 106 into the honeycomb member 107 usinga drill, for example. The insert 100A, B, C, D may then be positionedwithin the cavity 108 and an adhesive or other binding material may beinjected into the cavity 108 to secure the insert 100 to the honeycombmember 107. The insert 100A, B, C, D of the present disclosure mayadvantageously be used with interior panel 105 for an aircraft.

With reference to FIGS. 1-5, the insert 100A includes a housing 110having a first end 111 and a second end 112. The housing 110 defines acavity 115 that may be sized and shaped to accommodate a floating nut120 described in detail below. For example, the cavity 115 may have alower portion 116 configured to accommodate a second end 121 of thefloating nut 120 and a shoulder 117 to support a flange 122 at the firstend 123 of the floating nut 120 and to keep the second end 121 of thefloating nut 120 from contacting the housing 110. The housing 110 mayhave a two-piece construction mechanically joined together along a seam(not shown) via welding, such as a sonic weld, or via adhesive, forexample, to permit placement of the floating nut 120 into the cavity115. In addition, the two-piece housing may be joined together via amechanical interface such as by clips having cooperating male and femalecomponents. Still further, the seam of the two-piece housing should bedefined at a location to aid injection molding and manufacturing of thehousing.

The insert 100A further includes an aperture 125 defined in the firstend 111 of the housing 110. The aperture 125 is configured to permitaccess to the cavity 115 and may be sized and shaped to receive one orboth of a tip of an adhesive gun or male threaded fastening componentsuch as a screw.

The insert 100A also includes a semi-spherical portion 130 defined at asecond end 112 of the housing 110. This second end 112 is intended to beplaced in the cavity 108 of the panel 105 first such that the first end111 of the insert housing 110 faces out of the panel 105. Thesemi-spherical portion 130 may permit improved adhesive flowcharacteristics and seal with respect to the insert 100A and the cavity108 of the panel 105 by permitting an outward potting flow as discussedbelow with respect to method 200. The semi-spherical portion 130 mayalso reduce panel mark-off on a decorative side of the panel 105 byreducing the foot print of the second end 112 of the insert 100A.

Still further, the insert 100A includes a pair of vent openings 135defined on opposing sides of the first end 111 of the housing 110.During installation of the insert 100A in a panel 105, the vent openings135 may permit excess adhesive to exit the cavity 108 defined in thepanel 105. In one embodiment, the vent openings 135 may be configured toreceive the tip of an adhesive gun or other implement for adhesiveinjection, as described below with respect to method 200.

In one embodiment, the insert 100A may further include a pair oflongitudinally extending channels 140 defined on opposing sides of thefirst end 111 of the housing 110 and coupled to the pair of ventopenings 135. These channels 140 may help support the tip of an adhesivegun or other implement and may further help direct the adhesive out ofthe vent openings 135 during installation. In one embodiment, theinterior side 141 of the longitudinally extending channels may protrudeinto the cavity 115 of the housing 110 to act as stops to prevent thefloating nut 120 from rotating when a male member, such as a screw, isjoined with the floating nut 120, as described below.

The insert 100A may also include a plurality of retention protuberances145 coupled to and extending radially from the first end 111 of thehousing 110. These retention protuberances 145 may be nubs capable ofslight deformation to pass by a skin 106 (e.g., the skin 106 whichreceives the insert 100A, as represented by the upper skin 106 in FIG.5) of the panel 105. During installation, the retention protuberances145 may provide tactile feedback to the operator indicating the insert100A is at a proper depth within the cavity 108 of the panel 105. Theretention protuberances 145 may also prevent the insert 100 from backingout of the panel 105 in response to pressure from the adhesive.

Referring now to FIGS. 1-11, the insert 100A, B, C may further include acylindrical portion 150 at the first end 111 of the housing 110. Thecylindrical portion 150 may have a diameter the same as or slightlysmaller than the diameter of the cavity 108 defined in the panel 105. Inone embodiment, the diameter of the cavity 108 may be 0.001 incheslarger than the diameter of the insert, but one of skill in the artwould appreciate that a larger tolerance may be used in view of theadhesive flow that may fill any gap during installation. In oneembodiment, the cylindrical portion 150 of the housing 110 may have alarger diameter than the spherical portion 130 of the housing 110,similar to a flange.

The insert 100A, B, C may include a planar flat 155 defined on thespherical portion 130 of the second end 112 of the housing 110 andarranged opposite to the aperture 125. This planar flat 155advantageously reduces the foot print of the insert 100A, B, Cassociated with any mark-off that may occur on the panel skin 106 duringinstallation of the insert 100A, B, C. The planar flat 155 may alsoenable the insert to beneficially stand upright to aid in the use ofvibratory bowls and other automated feeding systems.

With reference to FIGS. 1-7, the insert 100A, B may include a pair ofreceptacles 160 coupled to the first end 111 of the housing 110. Each ofthe pair of receptacles 160 may have sidewalls 161 defining athrough-hole aligned with one of the pair of vent openings 135. In oneembodiment, the base 162 of each of the pair of receptacles 160 mayextend radially from the first end of the housing 110 such that thereceptacles 160 overhang the housing 110 and the base 162 may act asindexing surfaces against the skin 106 of the panel 105. In anotherembodiment, the sidewalls 161 of each of the pair of receptacles 160 mayextend away from the housing to capture any adhesive that overflowsduring installation. In another embodiment, the sidewalls 161 of thepair of receptacles 160 may be shaped like cones (FIGS. 1-5). In oneembodiment, the sidewalls 161 of the pair of receptacles 160 may beshaped like shallow cylindrical cups (FIGS. 6-7). The receptacles 160may be shaped to accommodate the tip of an adhesive gun or implement. Inaddition, during installation, the base 162 of each receptacle 160 maybe used to prevent the insert 100A, B from extending too far into thepanel 105. The receptacles 160 may also capture adhesive exiting thecavity 108 of the panel 105 during adhesive injection, therebypreventing the adhesive from spilling over onto the surface of the skin106. In a further embodiment, the pair of receptacles 160 may beconfigured to breakaway from the housing 110 via a thinned section or aweakened perforated coupling at the base 162.

Referring now to FIGS. 6-7 (which shows another embodiment of the insert100B), the insert 100B may also include an annular protuberance 165projecting radially from the spherical portion 130 of the housing 110.This annular protuberance 165 may increase the bond strength between thepanel 105 and the insert 100B, acting as an anchor about which theadhesive may flow and set.

With respect to FIGS. 8-11, which illustrate yet another embodiment, theinsert 100C may include a second aperture 170 defined in the second end112 of the housing 110 and aligned with a central axis of the sphericalportion 130. The first aperture 125, housing cavity 115 and secondaperture 170 together define a through-hole in the housing 110. In oneembodiment, the second aperture 170 may extend into the cavity 115 ofthe housing 110 and may define a receptacle 171 facing the first end 111of the housing 110. This receptacle 171 may be configured to receive thetip of an adhesive gun or similar implement to aid in the injection ofadhesive.

Referring now to FIGS. 12-17, which illustrate yet a further embodiment,the insert 100D may include a pair of helical grooves 175 defined on theexterior of the spherical portion 130 of the housing 110. The helicalgrooves 175 may permit pre-injected adhesive near the center of thecavity to advance upward when the insert 100D is installed, without theadhesive first having to advance downward or radially, thereby relievinginternal pressure in the panel 105. In one embodiment, each of the pairof helical grooves 175 may be coupled to one of the pair of ventopenings 135 to direct adhesive flow out of the cavity of panel torelieve back pressure from adhesive injection.

As shown in FIGS. 12-13, in one embodiment, the insert 100D may includea rigid tab 180 coupled to the first end 111 of the housing 110. Therigid tab 180 may have two openings 181 configured to align with andsurround the vent openings 135 of the insert 100D. The tab 180 may havea thickness ranging from 0.025 inches to 0.25 inches and may be made ofany rigid plastic or metal material, for example. These dimensions andmaterials may provide the tab with sufficient rigidity to not deform orflex when the insert is installed in the panel 105. This helps preventthe insert 100 from being pressed too deeply into the panel 105, therebypreventing mark-off on the panel skin 106. In various embodiments, therigid tab may be used in place of the pair of receptacles and viceversa.

In another embodiment, shown in FIGS. 2-3, 8-9, 11-12, 18A-18B, asdiscussed above, the insert 100A, B, C, D may include a threadedfloating nut 120 disposed within the cavity 115 of the housing 110. Thefloating nut 120, best seen in FIGS. 18A-B, defines a flange 122 at afirst end 123 and defines a through-hole 185 aligned with the apertureof the housing 110. The floating nut 120 has an inverted orientationrelative to the housing 110, when compared to other known floating nutsfor inset fasteners. Inverting the load-transmitting flange 120 in thismanner may permit the nut height to be shortened, reducing the totalweight of the insert 100 A, B, C, D. In one embodiment, the flange 122defines a pair of grooves 186 on opposing sides of the floating nutaligned with the pair of longitudinally extending channels 140 of thehousing 110. The grooves 186 on the flange 122 of the floating nut 120are sized and shaped to accommodate the interior side 141 of thelongitudinally extending channels 140 of the housing 110 that protrudeinto the cavity 108 of the housing 110 to act as stops to prevent thefloating nut 120 from rotating when a male member, such as a screw, isjoined with the floating nut 120. In another embodiment, threads definedat a second end 121 of the nut 120 may be deformed due depressions 187.These depressions 187 may be caused by application of pressure to aplurality of points around the second end 121 of the nut 120. In use,the depressions 187 may increase frictional forces acting on a malecoupling member (not shown), like a screw, thereby preventing the malecoupling member from backing out of the threads of the floating nut 120once the male coupling member has advanced past the second end 121 ofthe floating nut 120.

The second aspect of the invention provides methods for installing aninsert 100A, B, C, D into a panel 105 of an aircraft. In one embodimentshown in FIG. 19, a method 200 may include, at block 210, providing aninsert 100A, B that comprises (a) a housing 110 defining a cavity 115,(b) an aperture 125 defined in a first end 111 of the housing 110, (c) asemi-spherical portion 130 defined at a second end 112 of the housing110, (d) a pair of vent openings 135 defined on opposing sides of thefirst end 111 of the housing 110 and (e) a pair of receptacles 160coupled to the first end 111 of the housing 110, wherein each of thepair of receptacles 160 have sidewalls 161 defining a through-holealigned with one of the pair of vent openings 135. Then, at block 220,the insert 100A, B is installed in a cavity 108 of a panel 105 for anaircraft and advances until the pair of receptacles 160 rests against anexterior of a skin 106 of the panel 105 (see FIG. 5). In one embodiment,the spherical portion 130 may define a planar flat 155 that may restagainst the bottom of the cavity 108 of the panel 105 duringinstallation.

Next, at block 230, adhesive is injected into one of the pair of ventopenings 135. Adhesive will typically be injected via an adhesive gun orother implement having a tip that fits within one of the pair ofreceptacles 160 or pair of vent openings 135. And, at block 240,adhesive flows around the housing 110 until the adhesive exits thecavity 108 via the other one of the pair of vent openings 135.Application of the adhesive in this manner may permit an outward pottingflow with pressure directed radially rather than primarily against thebottom of the cavity 108 of the panel 105. This may beneficially helpreduce mark-off on the decorative surface of the panel 105.

With respect to an insert 100A, B that has a plurality of retentionprotuberances 145 coupled to and extending radially from the first end111 of the housing 110, method 200's step of installing the insert inthe cavity 108 of the panel 105 for the aircraft may include snappingthe retention nubs 145 past the exterior of the skin 106 to the cavity108 of the panel 105, in one embodiment. This arrangement mayadvantageously prevent the insert 100 from backing out of the cavity 108of the panel 105 in response to the pressure from the adhesive flow.

In another embodiment, after adhesive has been injected, method 200 mayinclude the application of a force to the pair of receptacles 160 toseparate the pair of receptacles 160 from the housing 110, as describedbelow with respect to method 400.

Referring now to FIG. 20, method 300 includes, at block 310, providingan insert 100C that comprises (a) a housing 110 defining a cavity 108,(b) an aperture 125 defined in a first end 111 of the housing 110, (c) asemi-spherical portion 130 defined at a second end 112 of the housing110, (d) a pair of vent openings 135 defined on opposing sides of thefirst end 111 of the housing 110 and (e) a second aperture 170 definedin a second end 112 of the housing 110 and aligned with a central axisof the spherical portion 112. Then, at block 320, the insert 100C isinstalled in a cavity 108 of a panel 105 for an aircraft. For example,the insert 100C may include a rigid tab 180 or a pair of receptacles 160coupled to the first end 111 of the housing 110. During installation,the insert 100C may be pressed into the cavity 108 until the rigid tab180 or the pair of receptacles 160 rest against an exterior of a skin106 of the panel 105, such that the second end 112 of the insert 100C isspaced apart from the bottom of the cavity 108 of the panel 105 topermit adhesive flow through the second aperture 170.

Next, at block 330, a tip of an adhesive gun is placed through the firstaperture 125 and the cavity 115 of the housing 110, and extend towardsthe second aperture 170 of the housing 110. In one embodiment, the tipof the adhesive gun may engage a receptacle defined by the secondaperture 170 (see FIG. 10). Then, at block 340, adhesive is injectedunderneath the spherical portion 130 of the insert 100C. This adhesiveis then flowed around the housing 110 until the adhesive exits thecavity 108 of the panel 105 via the pair of vent openings 135, at block350.

With respect to an insert 100C that has a plurality of retentionprotuberances 145 coupled to and extending radially from the first end111 of the housing 110, method 300's step of installing the insert 100Cin the cavity 108 of the panel 105 for the aircraft may include snappingthe retention nubs 145 past the exterior of the skin 106 to the cavity108 of the panel 105, in one embodiment. This arrangement mayadvantageously prevent the insert 100C from backing out of the cavity108 of the panel 105 in response to the pressure from the adhesive flow.

In another embodiment, the insert 100C may include a rigid tab 180 or apair of receptacles 160 coupled to the first end 111 of the housing 110.And method 300 may include the steps of applying a force to either therigid tab 180 or the pair of receptacles 160 and separating the rigidtab 180 or the pair of receptacles 160 from the housing 110, asdescribed below with respect to method 400.

Referring now to FIG. 21, method 400 includes, at block 410, providingan insert 100D that comprises (a) a housing 110 defining a cavity 115,(b) an aperture 125 defined in a first end 111 of the housing 110, (c) asemi-spherical portion 130 defined at a second end 112 of the housing110, (d) a pair of vent openings 135 defined on opposing sides of thefirst end 111 of the housing 110 and (e) a pair of helical grooves 175defined on the exterior of the spherical portion 130 of the housing 110(see e.g., FIGS. 12-17). Next, at block 420, adhesive is injected into acavity 108 of a panel 105 of an aircraft. The amount of adhesive may bepredetermined based upon the both the volume of the cavity 108 of thepanel 105 and the volume of the insert 100D itself. Alternatively, theadhesive may fill the cavity to a predetermined height. Further, theamount of adhesive used may be larger than the volume of the cavity 108remaining after the insert 100D is in place, to prevent voids in theadhesive between the panel 105 and the insert 100D. In addition,overfilling the cavity 108 may cause the adhesive to spill out of thepair of vent openings 135 signaling to an installer that the insert 100Dhas been properly seated within the cavity 108 (see block 440).

Then, at block 430, an insert 100D is installed in the cavity 108 of thepanel 105. In one embodiment, a rigid tab 180 may be coupled to thefirst end 111 of the insert's housing 110 and the insert 100D may beinstalled by pressing the insert 100D into the cavity 108 of the panel105 until the rigid tab 180 rests against an exterior of a skin 106 ofthe panel 105. In another embodiment, a pair of receptacles 160 may becoupled to the first end 111 of the insert's housing 110 and each of thepair of receptacles 160 may have sidewalls 161 defining a through-holeand aligned with one of the pair of vent openings 135. In thisembodiment, the insert 100D may be installed by pressing the insert 100into the cavity 108 of the panel 105 until the pair of receptacles 160rests against an exterior of a skin 106 of the panel 105. In a furtherembodiment, the insert 100D may be twisted during installation into thecavity 108 of the panel 105. The twisting action may help guide theadhesive along the pair of helical grooves 175. In another embodiment,an insert 100D may have a plurality of retention protuberances 145coupled to and extending radially from the first end 111 of the housing110, and method 400's installation step 430 may include snapping theretention nubs 145 past the skin 106 of the panel 105 to the cavity 108of the panel 105, in one embodiment.

At block 440, adhesive flows around the housing 110 and along the pairof helical grooves 175 until the adhesive exits the cavity 108 of thepanel 105 via the pair of vent openings 135. The helical grooves 175 maypermit the adhesive near the center of the cavity 108 to advance upwardwithout first having to advance downward or radially, thereby relievinginternal pressure in the panel 105.

In one embodiment, the method 400, after the adhesive has set in thecavity 108 of the panel 105, may further include applying a force to theunderside of the rigid tab 180 and then separating the tab 180 from thehousing 110. The force may be applied to the rigid tab 180 or to thepair of receptacles 160 using a scraper. This action severs the adhesivebond between the rigid tab 180 and the exterior of the panel skin 106and first end 111 of the housing 110, for example. In an alternativeembodiment, a force may be applied to the pair of receptacles 160,thereby separating the receptacles 160 from the insert's housing 110.The scraper may also sever a thinned section between the pair ofreceptacles 160 and the first end 111 of the housing 110, such that thepair of receptacles 160 and excessive adhesive, break away from theinsert housing 110. Alternatively, the force may be applied against thesidewalls 161 of the pair of receptacles 160, rotating the receptacles160 and severing the thinned section between the pair of receptacles 160and the first end 111 of the housing 110.

FIG. 22 is an illustration of a perspective view of an aircraft 500 thatmay incorporate one or more composite laminates manufactured by one ofthe embodiments of the present disclosure. As shown in FIG. 22, theaircraft 500 comprises a fuselage 512, a nose 514, a cockpit 516, wings518 operatively coupled to the fuselage 512, one or more propulsionunits 520, a tail vertical stabilizer 522, and one or more tailhorizontal stabilizers 524. Although the aircraft 500 shown in FIG. 22is generally representative of a commercial passenger aircraft, the oneor more inserts, as disclosed herein, may also be employed in othertypes of aircraft or air vehicles. More specifically, the teachings ofthe disclosed embodiments may be applied to other passenger aircraft,cargo aircraft, military aircraft, rotorcraft, and other types ofaircraft or aerial vehicles, as well as aerospace vehicles, satellites,space launch vehicles, rockets, and other aerospace vehicles. It mayalso be appreciated that embodiments of structures and methods inaccordance with the disclosure may be utilized in other transportvehicles, such as boats and other watercraft, trains, automobiles,trucks, buses, or other suitable transport vehicles formed from orutilizing the inserts as disclosed herein.

Embodiments of the disclosure may find use in a variety of potentialapplications, particularly in the transportation industry, including forexample, aerospace, marine, automotive applications and otherapplication where the one or more inserts may be used. Therefore,referring now to FIGS. 23-24, embodiments of the disclosure may be usedin the context of an aircraft manufacturing and service method 630 asshown in FIG. 23 and an aircraft 650 as shown in FIG. 24. Aircraftapplications of the disclosed embodiments may include, for example,without limitation, the design of inserts and methods for installationthereof as disclosed herein.

During pre-production, exemplary method 630 may include specificationand design 632 of the aircraft 650 and material procurement 634. As justone example, for the specification and design of the aircraft-relatedinserts 100, floating nuts 120, panels 105 and methods 200, 300, 400disclosed herein, may be determined at this step.

During production, component and subassembly manufacturing 636 andsystem integration 638 of the aircraft 650 takes place. As explained ingreater detail above, FIGS. 1-18 illustrate preferred types of inserts100A, B, C, D for assembling a panel 105 for the aircraft 650 inaccordance with one aspect of the present disclosure. After such acomponent and subassembly manufacturing step, the aircraft 650 may gothrough certification and delivery 640 in order to be placed in service642. While in service by a customer, the aircraft 650 is scheduled forroutine maintenance and service 644, which may also includemodification, reconfiguration, refurbishment, and so on.

Each of the process steps of exemplary method 630 may be performed orcarried out by a system integrator, a third party, and/or an operator(e.g., a customer). For the purposes of this description, a systemintegrator may include without limitation any number of aircraftmanufacturers and major-system subcontractors; a third party may includewithout limitation any number of vendors, subcontractors, and suppliers;and an operator may be an airline, leasing company, military entity,service organization, and so on.

As shown in FIG. 24, the aircraft 650 produced by exemplary method 630may include an airframe 652 with a plurality of high-level systems 654and an interior 656. Examples of high-level systems 654 may include oneor more of a propulsion system 658, an electrical system 660, ahydraulic system 662, and an environmental system 664. Any number ofother systems may be included. Although an aerospace example is shown,the principles of the disclosure may be applied to other industries,such as the marine and automotive industries.

Apparatus, systems and methods embodied herein may be employed duringany one or more of the stages of the aircraft manufacturing and servicemethod 630. For example, components or subassemblies corresponding toproduction process may be fabricated or manufactured in a manner similarto components or subassemblies produced while the aircraft 650 is inservice. Also, one or more apparatus embodiments, method embodiments, ora combination thereof may be utilized during the production stages 632and 634, for example, by substantially expediting assembly of, orreducing the cost of, an aircraft 650. Similarly, one or more ofapparatus embodiments, method embodiments, or a combination thereof maybe utilized while the aircraft 650 is in service, for example andwithout limitation, for maintenance and service 644 of the aircraft.

It is intended that the foregoing detailed description be regarded asillustrative rather than limiting and that it is understood that thefollowing claims including all equivalents are intended to define thescope of the invention. The claims should not be read as limited to thedescribed order or elements unless stated to that effect. Therefore, allembodiments that come within the scope and spirit of the followingclaims and equivalents thereto are claimed as the invention.

We claim:
 1. A method for using an insert that comprises (a) a housingdefining a cavity, (b) an aperture defined in a first end of the housingto the cavity, (c) a semi-spherical portion defined at a second end ofthe housing, (d) a pair of vent openings defined on opposing sides ofthe first end of the housing and (e) a pair of receptacles coupled tothe first end of the housing, wherein each of the pair of receptacleshave sidewalls defining a through-hole and aligned with one of the pairof vent openings, the method comprising: installing the insert in acavity of a panel for an aircraft and advancing the insert until thepair of receptacles rests against an exterior of a skin of the panel;injecting adhesive into one of the pair of vent openings; and flowingthe adhesive around the housing until the adhesive exits the cavity viathe other one of the pair of vent openings.
 2. The method of claim 1,wherein the insert further comprises (e) a plurality of retentionprotuberances coupled to and extending radially from the first end ofthe housing; and wherein installing the insert in the cavity of thepanel for the aircraft comprises snapping the retention nubs past theexterior of the skin to the cavity of the panel.
 3. The method of claim1, further comprising: applying a force to the pair of receptacles; andseparating the pair of receptacles from the housing.
 4. The method ofclaim 3, wherein applying a force to the pair of receptacles comprisesrotating the pair of receptacles thereby severing a thinned sectionbetween the pair of receptacles and the first end of the housing.
 5. Themethod of claim 1, wherein the insert further comprises (e) a planarflat defined on the semi-spherical portion of the second end of thehousing and arranged opposite to the aperture; and wherein installingthe insert in a cavity of a panel for an aircraft comprises resting theplanar flat against a bottom of the cavity.
 6. The method of claim 1,wherein flowing the adhesive around the housing includes an outwardpotting flow of the adhesive with pressure directed radially.
 7. Amethod for using an insert that comprises (a) a housing defining acavity, (b) a first aperture defined in a first end of the housing tothe cavity, (c) a semi-spherical portion defined at a second end of thehousing, (d) a pair of vent openings defined on opposing sides of thefirst end of the housing and (e) a second aperture defined in a secondend of the housing and aligned with a central axis of the semi-sphericalportion, the method comprising: installing the insert in a cavity of apanel for an aircraft; placing a tip of an adhesive gun through thefirst aperture and the cavity of the housing to the second aperture ofthe housing; injecting adhesive underneath the semi-spherical portion ofthe insert; and flowing the adhesive around the housing until theadhesive exits the cavity of the panel via the pair of vent openings. 8.The method of claim 7, wherein the insert further comprises (f) aplurality of retention protuberances coupled to and extending radiallyfrom the first end of the housing; and wherein installing the insert inthe cavity of the panel for the aircraft comprises snapping theretention nubs past the exterior of the skin to the cavity of the panel.9. The method of claim 7, wherein the insert further comprises (f) aplanar flat defined on the semi-spherical portion of the second end ofthe housing and arranged opposite to the aperture; and whereininstalling the insert in a cavity of a panel for an aircraft comprisesresting the planar flat against a bottom of the cavity.
 10. The methodof claim 7, wherein placing a tip of an adhesive gun through the firstaperture and the cavity of the housing to the second aperture of thehousing further comprises the tip of the adhesive gun engaging areceptacle defined by the second aperture.
 11. The method of claim 7,wherein the insert further comprises (f) a pair of vent openings definedon opposing sides of the first end of the housing, the method furthercomprising: applying a force to the pair of receptacles; and separatingthe pair of receptacles from the housing.
 12. A method for using aninsert that comprises (a) a housing defining a cavity, (b) an aperturedefined in a first end of the housing to the cavity, (c) asemi-spherical portion defined at a second end of the housing, (d) apair of vent openings defined on opposing sides of the first end of thehousing and (e) a pair of helical grooves defined on an exterior of thesemi-spherical portion of the housing, the method comprising: injectingadhesive into a cavity of a panel of an aircraft; installing the insertin the cavity of the panel; and flowing adhesive around the housing andalong the pair of helical grooves until the adhesive exits the cavity ofthe panel via the pair of vent openings.
 13. The method of claim 12,further comprising: twisting the insert in the cavity of the panel. 14.The method of claim 12, wherein the insert further comprises (f) a rigidtab coupled to the first end of the housing; and wherein installing theinsert in the cavity of the panel for the aircraft comprises pressingthe insert into the cavity of the panel until the rigid tab restsagainst an exterior of a skin of the panel.
 15. The method of claim 12,further comprising: setting the adhesive in the cavity of the panel;applying a force to an underside of the rigid tab after the adhesive hasset; and separating the tab from the housing.
 16. The method of claim12, wherein the insert further comprises (f) a pair of vent openingsdefined on opposing sides of the first end of the housing, the methodfurther comprising: applying a force to the pair of receptacles byrotating the pair of receptacles thereby severing a thinned sectionbetween the pair of receptacles and the first end of the housing; andseparating the pair of receptacles from the housing.
 17. The method ofclaim 12, wherein injecting adhesive into a cavity of a panel of anaircraft comprises injecting a predetermined amount of adhesive based ona volume of the cavity of the panel and a volume of the insert.
 18. Themethod of claim 12, wherein injecting adhesive into a cavity of a panelof an aircraft comprises filling the cavity to a predetermined height.19. The method of claim 12, further comprising: overfilling the cavityand causing the adhesive to spill out of the pair of vent openingsthereby signaling the insert is properly seated within the cavity. 20.The method of claim 12, wherein the insert further comprises (f) aplurality of retention protuberances coupled to and extending radiallyfrom the first end of the housing; and wherein installing the insert inthe cavity of the panel for the aircraft comprises snapping theretention nubs past the exterior of the skin to the cavity of the panel.